Method of forming fireproof building construction.



F. w. HARGRAVE & J. A. WHEELER. METHOD OF FORMING FIREPROOF BUILDING CONSTRUCTION.

APPLICATION FILED MAN- 5. I914.

Patented uly 24 25 75 g 2 E E FEED W. HGVE, OI? SOUTH RIVER, AND JAMES A. M

EELER, OF SOMERSET COUNTY, NEW JERSEY, ASSIGNORS T WILLIAM '1. ELK ill TON, 01E PHILADEL rnra, rnuu'srtvame.

specification of Letters Patent.

Patented duly 2d, 1191?,

Application filed March a, ma. Serial no. team.

To all whom it may concern:

Be it known that we, FRED W. RoRAvn, a resident of. South River, in the county of Middlesex and State of New Jersey, and Janus A. Waterline, a resident of the county of Somerset, in the State of New Jersey, both citizens of the United States, have invented certain new and useful Improvements in Methods of ForminFireproof Building- Construction, such as oors, Trim, or the like, of which the following is a specification.

This invention relates to methods of forming fireproof building construction, such as doors, trim, or the like, and it has special relation to the forming or production of articles designed to be used in fireproof building construction and which combine an artificial fireproof lumber or composition and metallic elements.

Our improved method is adapted for edective employment or use in forming all types of articles or devices for use in fireproof building construction, such as doors, door frames, window and sash frames, trim, or the like, and inthe accompanying illustration of the method we have shown its application to the forming of one type of ing an artificial fireproof lumber or composition and metallic elements, the artificial fireproof lumber or composition has been molded and compressed into shape to produce a construction in which it forms the exterior surface of the door or other article, and the metallic elements have been contained within the interior space of such exterior composition structure, as bracing elements, for instance as shown and described in the previous applications of James A. Wheeler, Serial No. 676,817, filed February 10, 1912, Serial No. 676,818, filed February 10, 1912, and Serial No. 770,809, filed May 31, 1913. Fireproof doors and other articles of this class have also been heretofore constructed with metallic casings in which are placed internal body structures of wood or other material to form a bracing.

The object of our present invention is to provide a simple and improved method whereby such doors or other articles for use in fireproof building construction may be structions.

readily and economically formed with an external metallic casin or sheathing inclosmgand carrying an mternal body structure formed of an artificial fireproof lumber or composition, and to these ends the leadmg feature of our improved method conslsts 1n the molding of the artificial fireproof lumber or composition directly within the external metallic casing or sheathing and compressing and drying the composition in a rigid structure within the mold formed by the external metallic casing or sheathing of the finished article, substantially as hereinafter described and particularly pointed out in the claims.

In carrying out our improved method, the internal fireproof body structure, which is molded and compressed and dried in a rigid structure within a mold formed by the external metallic casing or sheathing of the finished article, is formed of artificially united substances having a fireproof quality and which are solidified and compressed and dried in a rigid structure so that suflicient density and strength will be imparted to efiectually resist the strains and other conditions which are encountered in the employment of-the device or article in building con- For this purpose, we prefer to use the composition which is commercially known as alignum and which is constituted by a suitable filler including asbestos and combined with a fireproof binderto produce a plastic substance which is molded into shape and compressed and dried in a rigid structure, and which forms a rigid nonmetallic composition of low heat conductivity and undeformable by heat, said alignum composition being described in its general characteristics in the patent to James A. Wheeler, for an improved method of forming fireproof slabs or boards, No. 1,048,616, dated December 31, 1912. As described in said patent, this artificial lumber or composition material preferably consists of a filler including burnt clay broken into small particles or crushed into a pulverized condition though any other suitable or adapted substance may be employed, and said filler is then mixed or compounded with asbestos in suitable or desired proportion, and there is then added to the compound or mixture a relatively small proportion of a suitable soluble fireproof binding material which will permanently unite the elements of the mass, for instance the binding material preferably consists of or mcludes silicate of soda. After the plastic mass is compounded and thoroughly mixed to a proper consistency, it is adapted to be molded into the desired general shape or form, and is then compressed and hardened and dried to the desired degree of density. The fireproof composition of the characteristics as just stated is therefore adapted ing and compressing the internal fireproof composition body structure within the mold constituted by the external metallic cas ng or sheathing, parts being shown 1n sectlon to illustrate the structural features.

Fig. 2 is a detail cross-section, on an enlarged scale, taken through the cas ng or sheathing and the composition therem and the molding and compressing elements.

Fig. 3 is a top or plan view, llustrating the base construction within which the external metallic casing or sheathing is placed and showin the latter therein in position to form the mold.

Fig. 4 is a detail cross-section, on an en- 'larged scale, through a complete door as formed by the two corresponding half-sections produced under our improved method. Corresponding parts in all the figures are denoted by the same reference characters.

Referring to the drawings, 1 designates a type of press which may be employed in carrying out our improved method. Said press preferably comprises steam chambers, as at 22, for the purpose of producing the drying action upon the fireproof composition 'or substance which is molded and compressed and solidified and hardened within the mold formed by the external metallic casing or sheathing of the finished article.

Into said chambers steam is introduced by means. of communicating tubes or pipes, 3, and the press has a suitable bed or base, 4,

and a follower, 5, controlled by a screw, 6, operating in a cross-head, 7, to exert the de- .sired degree of pressure in the molding and drying oneration.

In the preferred arrangement for carrying out our improved method for forming fireproof doors or analogous articles, as

1 pressed an The plastic fireproof composition, as hereaaaaaec herein shown, the steam chamber is mounted above the bed 4, and its top surface forms a table, as at 8, upon which a smooth metallic late or sheet, 9, is placed. A metallic me or' form, 10, conforming to the outline or shape of the door or analogous article, is carried by the base plate 9 and is preferably constituted by a series of metalhc bars, 11, projecting at the top surface of the plate 9 and detachably or adjustably secured thereto by screws or bolts, 12, said bars being .relativ'ely arranged to form a frame some;

what larger than the size of the door which 1s to be produced. Metallic strips, 14, preferably formed of steel are nlaced within the frame 10 to'occupy the space between the inner edge thereof and the edge portion of the door which is to be produced, these strips being 1n loose position and resting upon the base plate 9 so that they are readily removable to enable the removal of the finished half-section of the door after the molding and pressing and drying operation.

A metallic plate or sheet, 15, adapted to form the external casing or sheathing of the finished door is placed within the form constituted by the surrounding strips 14. This casing sheet is substantially pan-shape-and is bent to form a base portion, as at 16, resting upon the top surface ofthe base plate 9 and adapted to form the side surface of the door, and upwardly-turned projecting edge portions, 17 resting against the strips 14 and adapted to form the edge portion of the door, the top edges of said projecting portlons 17 being preferably turned inwardly at an angle to form a projecting retaining flange, as at 18, to facilitate the retention of the fireproof composition during the molding operation and after it is comdried in position.

inbefore set forth, which constitutes the internal body structure of the completed door construction, is shown at 19, and is troweled or otherwise filled in to a suitable height into the mold formed by the metallic plate or sheet 15 which constitutes the external casing or sheathing of the completed door structure. Suitable plungers or cores, 20, of proper and desired size and shape, are then placed and relatively positioned upon the plastic mixture 19 within the casing mold 15, these plungers being of proper contour and spaced as desired to-form the internal body shapeand structure which is constituted by the fireproof composition. Said plungers are provided with vertical perforations 21, to permit the moisture or steam to effectually escape from the plastic composition mass 19 during the molding and compression thereof to harden and dry the same. A'sheet of wire netting, as at'22, is

preferably placed to extend over the bottom of the respective plungers or cores 20, to prenaaeaoo vent the plastic composition 19 from enter ing the perforations 21, which wire netting may be left in the composition body structure 19 after the compressing and. drying operation thereon.

Over the top of the set of plungers or cores 20, and covering the full top area of the casing mold 15, is placed a metallic plate, 23, having perforations, 24, to permit the efi'e'ctive escape of the steam or moisture passing thereto from the underlying per forated plungers and the plastic composition 19. Said perforated plate 23 also acts as a former for the top surface of the internal composition bodystructure 19. lhe perforations of the plate 23 are relatively smaller than the perforations 21 of the plungers 20, inasmuch as it is desirable to leave a. smooth and approximately even surface at the top of the internal composition body structure 19, which surface will not be impaired by the relatively-small perforations of the former plate 23, while the provision of the relatively-large perforations in the plungers or cores permits the efiective escape of the moisture or steam from the body mass of the plastic 19.

Over the perforated plate 23 is placed wire netting preferably consisting of a plurality of two or more crossed sheets of netting, as at 25-25, to permit the moisture or steam escaping at the top of the plate 23 to pass off laterally from the elements arranged in the press. Upon the wire netting 25 is placed another metal plate or sheet, 26, which forms a top surface to separate the underlying elements from the next steam chamber 2 which is mounted immediately above-said plate 26.

If desired, the relative arrangement of elements as hereinabove described may be continued in tiers in the press, to enable the formation of a plurality of door sections or other articles in one operation of the press, as will be readily understood.

After the relative arrangement of the various elements in the press, as above described, then by opera ting the follower 5 the elements in the press are subjected to the required pressure to force the plungers or cores20 to their proper action upon the plastic fireproof composition 19, to mold and produce the desired shape or form of the internal fireproof structure of the door and to effectually compress the same within the mold formed by the external casing plate or sheathing 15 of the completed door structure, and to solidify and harden and dry, under the required pressure and heat, the molded composition 19 in a rigidstructure which is of fireproof quality and of low heat conductivity and undeformable by heat.

It will be understood that the press as employed in our improved method may be of any well-known hydraulic or steam power type, whereby high pressures may be edecter hereinbefore mentioned, the type of door is substantially that shown in our applications for patent Serial No. 815,141, filed January 29,1914, and Serial No. 815,140, filed January 29, 1914, the completed door of this type as shown in said first-mentioned application being herein illustrated in the cross-section in Fig. 4. A door of this type is constituted by two corresponding halfparts or sections, 2727,' each of which halves comprises the thin metallic casing or sheathing plate 15 forming the external surface of the door at the face or side and at half of the edge portion thereof, the two corresponding half-sections being secured together adhesively or otherwise, as at 28, at the abutting faces of the internal fireproof composition body structure 19 which is molded within the external casing or sheathing 15. The internal body structure of this type of door is molded to form a relatively-thin base portion, 29, extending against and over the area of the base portion 16 of the sheathing plate 15, and thickened edge portions, as at 30, forming continuous blocks or bars extending around the edge portions 17 of the sheathing plate 15, whereby an interior open area or space, as at 31, will be formed interiorly of the door, in which open area or space extend bars or blocks, as at 32, in parallel position at suitable intervals and continuously between the thickened edge-portions 30. Therefore, it will be understood that, in constructing this type of door under our present improved method as herein described, the plungers or cores 20 are placed and positioned to pro duce the desired construction and features of the internal body structure 19 as, above set forth. It will further be understood that the half-sections of this type of door are separately formed in the press, according to the improved method herein described, and are assembled and secured together after such half-sections are removed from the press, to form the completed door.

Our improved method is adapted for effectively producing any specific form of molded article or device for use in fireproof building construction, combining an internal fireproof body structure molded and compressed and dried in an extern almetallic casing or sheathing, it being simply necessary to vary the shape of the mold constituted by the casing plate or sheet/15 and the shape and relative position of the plungers or cores 20 to produce the desired varied forms of any article or device of this type for use in building construction.

The advantages of our improved method of forming fireproof building constructlon, as herein described, will be readlly understood by those skilled in the art to which it appertains. The improvements enable the ready and economical manufacture of the sections of articles for fireproof buildmg construction, which combine an internal fireproof body structure with an external metallic casing or sheathing, in one operation, by directly molding the internal fireproof composition body structure within the mold formed by the external metallic casing or sheathing ofthe completed article, and also in the one operation the efi'ectual compressing and drying and hardening of the plastic composition, which forms the molded internal fireproof body structure, in permanent association with the external metallic casing or sheathing and in a rigid structure of the requisite density and of low heat conductivity and undeformable by heat.

We do not desire to be understood as limiting ourselves to the detail features and conditions of operation of the steps of the improved process as herein shown and described, as it is manifest that variations and modifications therein, may be resorted to, in the adaptation of our invention to varying conditions of use, without departing from thespirit and scope of our invention and improvements. We therefore reserve the right to all such vvariations and modifications as properly fall within the scope of our inven tion and the terms of the following claims. Having thus described our invention, we

claim and desire to secure by Letters Patcomposition while in said external surface sheathing mold to the action ofplungers or cores and the requisite pressure to produce the desired structural molded shape of the internal body structure and to compress and harden the same in its completed molded shape within the external casing mold to the desired degree of density.

2. The method of forming fireproof building construction, such as doors, trim, or the like, which consists in molding a plastic sub stance consisting of a fireproof composition, which forms the internal body structure of the completed article, within a mold constituted by a metallic casing or sheathing which forms the external surface of the completed.

article, and subjecting said plastic composition while in said external surface sheathing mold to the action of plungers, which are perforated to permit the escape of moisture rom the plast1c composition, and to the action of heat and to the requisite pressure to produce the desired structural molded shape of the internal, body structure and to compress and harden and dry the same in its completed molded sha e within the external casing mold to the deslred degree of density.

3. The method of forming fireproof building construction, such as doors, trim, or the like, which consists in molding a plastic substance consisting of a fireproof composition, which forms the internal body structure of the completed article, within a mold constituted by a metallic casing or sheathing which forms the external surface of the completed article, and subjecting said plastic composition while in said external surface sheathing moldto the action of plungers,which are perforated to permit the escape of moisture from the plastic composition and in association with a sheet of wire netting extending between the bottom of the plungers and the plastic substance to prevent the passage of the latter to said perforations, and to the action of heat and to the requisite pressure to produce the desired structural molded shape of the internal body structure and to compress and harden and dry the same in its completed molded shape within the external casing mold to the desired degree of density.

4. The method of forming fireproof building construction, such as doors, trim, or the like, which consists in .molding a plastic substance consisting of a fireproof composition, which forms the internal body structure of the completed article, within a mold constituted by a metallic casing or sheathing which forms the external surface of the I forations therein and across the top area of the casing mold to permit the escape of moisture from the plastic composition and to serve as a former for the top surface of the internal composition body structure, and to the action of heat and to the requisite pressure to produce the desired structural molded shape of the internal body structure and to compress and harden and dry the same in its completed molded shape within the external casing 'mold to the desired degree of density.

'5. The method of forming fireproof building construction, such as'doors, trim, or the like, which consists in molding a plastic substance consisting of a fireproof compo- 'sition, which forms the internal body structure of the completed article, within a mold constituted by a metallic casing or sheathing which forms the external surface of the com pleted article, and subjecting said plastic composition while in said external surface sheathing mold to the action of plungers, which are erforated to permit the escape of moisture f i-om the plastic composition and in association with a rforated metallic plate extending across e top of the plungers and intersecting the perforations therein and across the top area of the casing mold to permit the escape of moisture from the plastic composition and to serve as a former for the top surface of the internal composition body structure, and also in association with a sheet of wire netting extending over the area of said former-plate to permit the escape of moisture from the perforations thereof, and to the action of heat and to the requisite pressure to produce the desired structural molded shape of the internal body structure and to compress and harden and dry the same in its completed molded shape within the external casing moldvto the desired degree of density. v,

6. The method of forming fireproof building construction, such as doors, trim, or the like, which consists in mounting in a suitable press and in association with heated chambers or plates a mold constituted by a metallic casing or sheathing which forms the external surface of the completed article, placing within said external surface sheathing mold a plastic substance consisting of a fireproof composltion which forms the internal body structure of the completed article, said casing mold and lastic substance bein mounted and place in association with p ungers or cores operative upon .said plastic substance, and then subjecting internal body structure and to the requisite pressure and action of heat to compress and harden and dry the same in its completed molded shape within the external casingmold to the desired degree of density.

7 The method of forming fireproof building construction, such as doors, trim, or the like, which consists in forming two corresponding half-sections each respectively produced by molding a plastic substance consisting of a fireproof composition, which forms the internal body structure of the half-section of the completed article, within a mold vconstituted by a metallic casing or sheathing which forms the external surface of the half-section of the completed article, and subjecting said plastic composition while in said external surface sheathing mold to the requisite pressure to roduce the desired structural shape of the mternal body structure and to compress and harden the same in its completed shape within the external casing mold to the desired degree of density, and then securing the corresponding half-sections together with their inner molded surfaces of the internal composition body structures abutting.

In testimony whereof we have signed our names in the presence of the subscribing witnesses.

FRED w. HARGRAVE. JAMES A. WHEELER. 

